SERVICE MANUAL. Pallet Trucks
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1 SERVICE MANUAL Pallet Trucks 8HBW30 40,001 and up 8HBE30 40,001 and up 8HBE40 40,001 and up 8HBC30 40,001 and up 8HBC40 40,001 and up 8TB50 40,001 and up CL Issued: 6 May 2013
2 2013 by Toyota Industrial Equipment All rights reserved. No portion of this manual may be reproduced mechanically, electronically or by any other means, including photocopying, electronic retrieval or transfer, or recording without the written permission of the publisher. Toyota Industrial Equipment believes the information in this manual is accurate and current as of the publication date; such information is subject to change without notice. Toyota Industrial Equipment is not responsible for any errors that may appear in the manual CL Issued: 6 May B
3 Service Manual Change History Description Page # Date 1 Split out service manual sections all 6/30/13 2 Updated Information Bulletins page 3 11/30/13 3 Updated Information Bulletins page 3 1/31/14 4 Updated Information Bulletins page 3 3/31/14 5 Updated Information Bulletins page 3 7/31/14 6 Updated Information Bulletins page 3 8/15/14
4 Service Information Bulletin 1 SIB BF10-003R Tractor Cover Mounting update kit Section 7 2 SIB BF Fork Crack Repair For Demanding Applications Section 7 3 SIB BR Fixed Handle Adjustable Brake Potentiometer Section 7 4 SIB BR Handle Operating Range Section 7 5 SIB CC Pre-Programmed ETAC Card No Longer Available Section 7 6 SIB CC Software Update Information and Descriptions Section 6 7 SIB CC Power Steering Software Update (V1.9) Section 6 8 SIB CC HBC & 8TB50 Floormatt Switch Operation Section 3 & 8 9 SIB CC Power Steering Unit Repair Instructions Section 6 & 7 10 SIB CE C81 Code Steer Potentiometer Section 6 11 SIB CC Vehicle Manager and Traction Amp Software Updates Section 6 12 SIB CE Twist Grip Shimming Section 7 13 SIB CE Power Steer Handle Bezel Update Section 7 14 SIB CE Solid State Steering Potenitomenter Instructions Section 7 Technical News Brief 1 TNB Setting Parameters in ETAC Card Units 2 TNB Change To All Metric Hardware 3 TNB Tandem Load Wheel Block Grease Fitting 4 TNB Excessive Throttle Play In Neutral 5 TNB Steer Bearing Shimming 6 TNB Use of Loctite on Pinion Nut 7 TNB Motor Controller Overtemp Hotline Tech Tips 1 HTT Parameters 2 HTT Pinched Drive Motor Cables 3 HTT Using Loctite on Pinion Nut 4 HTT Truckcomm Software 5 HTT Drive Unit Tightening Sequence 6 HTT Rebuilding Cast style Lift cylinder 7 HTT Water In Grab Rail 8 HTT Gluing of Cushioned Floor Mat 9 HTT Travel Speed And Acceleration Parameters 10 HTT Fix For Loose Keyless Switch 11 HTT Curtis Handset Connection Procedure 12 HTT Static Return To Off; Reducing Steer Effort 13 HTT Parameter 24 Explained 14 HTT Greaseable Steer Bearing 15 HTT Motor Temperature Sensor Replacement 16 HTT Programming ETAC Card; Troubleshooting AMP LED Codes 17 HTT New ETAC Card Installation
5 Toyota Pallet Truck Service Manual Table of Contents Table of Contents Document Revision History xi How To Use This Manual Map of the Manual Manual Design Abbreviations & Symbols START Page Safety Definitions General Safety Battery Safety Jacking Safety Fork Section Tractor Section Tie-Down for Transport Towing Without Brake Release Bolts With Brake Release Bolts Static Safety Welding Safety Systems Overview Introduction Truck Model Identification Lift Truck Specifications Special Tools Service Key Operator Display and Programming Special Truck Mode Hour Meter (H) Error Codes (E) Changing Truck Parameters (P) Service Input/Output Displays Digital Inputs/Outputs from Traction Amplifier and VM Toyota FlashWare Overview Requirements Installing FlashWare on PC Connecting PC to Truck Starting FlashWare Planned Maintenance Maintenance Guidelines Initial 90 Day/250 Deadman Hours (HD) Maintenance Every 180 Days or 500 Deadman Hours Every 360 Days or 2000 Deadman Hours (HD) Contactor Tip Inspection Grease Fittings (All Models) Grease Fittings (Trucks without Composite Bushings Only) Undercarriage Pin and Bushing Inspection Points CL398-13, Issued: 6 May 2013 i
6 Table of Contents Toyota Pallet Truck Service Manual Troubleshooting How to Use This Section Troubleshooting Flowcharts TS1: START TROUBLESHOOTING GEN1: General Troubleshooting END1: End of Troubleshooting Procedure Electrical Troubleshooting Guidelines General Troubleshooting the CAN Bus Shorts to Frame Test Fuses Test/Inspection DC Electric Motors DC Motor Types Inspection Service Open Circuit Motor Test Grounded Motor Test Short-Circuited Armature Short-Circuited Winding AC Electric Motors AC Motor Type Open Winding Shorted Winding Hydraulic Troubleshooting Guidelines Symptom Tables: Lift/Lower System Symptom Tables: Travel (Forward/Reverse) System Symptom Tables: Wiring System Messages and Codes List of Messages and Codes Traction Amplifier LED Diagnostics Traction Amplifier Flash Codes Caution and Error Codes Caution Codes Code GATE Code SLO Code Sro (C14) Code C Code HPd (C20) Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C ii CL398-13, Issued: 6 May 2013
7 Toyota Pallet Truck Service Manual Table of Contents Code C Code C36 (Model 8TB50 with Power Steer) Code Lo (C41) Code Hi (C42) Code Hot1 (C44) Code Hot2 (C45) Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C Code C74 (Model 8TB50 with Power Steer) Code C75 (Model 8TB50 with Power Steer) Code C76 (Model 8TB50 with Power Steer) Code C77 (Model 8TB50 with Power Steer) Code C78 (Model 8TB50 with Power Steer) Code C79 (Model 8TB50 with Power Steer) Code C80 (Model 8TB50 with Power Steer) Code C81 (Model 8TB50 with Power Steer) Code C82 (Model 8TB50 with Power Steer) Code C83 (Model 8TB50 with Power Steer) Code C84 (Model 8TB50 with Power Steer) Code C85 (Model 8TB50 with Power Steer) Code C86 (Model 8TB50 with Power Steer) Code C87 (Model 8TB50 with Power Steer) Code C88 (Model 8TB50 with Power Steer) Code C89 (Model 8TB50 with Power Steer) Code C90 (Model 8TB50 with Power Steer) Code C94 (Model 8TB50 with Power Steer) Error Codes Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E CL398-13, Issued: 6 May 2013 iii
8 Table of Contents Toyota Pallet Truck Service Manual Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Code E Component Procedures List of Component Procedures by Truck System Component Locator Photos Steering and Controls Electric Power Steering Replacing the Pinion Gear Replacing the Power Steer Unit Learn Steer Checking the Steer Position Steer Home Proximity Sensor (SW23) Electric Power Steer Handle and Post Assembly Control Head Control Handle - Model 8HBW Control Handle Disassembly Changing Horn Button/Switch Changing Lift/Lower Button Changing Push Button Spring-Loaded Handle Design - Models 8HBE30/ Removal Installation Fixed-Position Handle Design - Models 8HBC30/40 and 8TB Removal Installation Control Handle Assemblies - Models 8HBE, 8HBC, and 8TB Control Head Removal Changing Horn Button/Switch Changing Lift/Lower Switch Activator Changing the Push Button Changing the Jog Trigger Switch Changing the Jog Trigger and Spring Throttle Spring Replacement iv CL398-13, Issued: 6 May 2013
9 Toyota Pallet Truck Service Manual Table of Contents Drive and Brake Drive Unit Drive Unit Removal Steering Bearing Removal Steering Bearing Installation Drive Unit Disassembly Drive Unit Assembly Checking the Gears Adjusting Tooth Pattern of Drive Unit Drive Unit Installation Drive Housing Lubrication Drive Wheel Removal Cushion Tire Replacement Shim Caster Adjustment Adjustable Caster Adjustment Casters (Poly Block) Caster Removal Wheel Replacement Caster Installation Casters (Spring-Loaded) Spring-Loaded Caster Removal Wheel Replacement Caster Disassembly Caster Assembly Wheel Installation Spring-Loaded Caster Installation Brake Brake Removal Brake Installation Checking the Gap Replacing the Rotor Electrical Components Battery Trucks With Battery Gates and Rollers (Optional) Battery Gates (Optional) Battery Rollers (Optional) Trucks Without Battery Gates and Rollers Battery Exterior Cleaning Testing, Charging, and Maintenance Maintenance-Free Batteries Battery Storage Power Cables Wiring Harness Wiring Harness Inspection Wiring Harness Repair AMP Water-Resistant Connectors AMP Connector Pin Extraction AMP Connector Pin Insertion AMP Connector Seals CL398-13, Issued: 6 May 2013 v
10 Table of Contents Toyota Pallet Truck Service Manual AMP Harness/Traction Amplifier Connector AMP Harness Connector Components AMP Harness Connector Disassembly (Contact Removal) AMP Harness Connector Assembly Testing AMP Harness Connectors Brake Potentiometer (VR1) VR1 Removal VR1 Installation Brake Potentiometer Calibration Lift-Limit Switch (SW8) Limit Switch Adjustment Grab Rail Switches - Model 8HBE30/ Grab Rail Switch Module Removal Grab Rail Switch Module Installation Load Backrest Switches - Model 8HBC30/40 Option Removing Load Backrest Switches Installing Load Backrest Switches Hydraulic Solenoids Jog Pick Solenoid - Model 8HBE30/40 Option Jog Pick Solenoid Removal Jog Pick Solenoid Installation Jog Pick Solenoid Switch/Spring Jog Pick Switch/Spring Removal Jog Pick Switch/Spring Installation Jog Pick Canister Jog Pick Canister Removal Jog Pick Canister Installation Jog Pick Canister Repair Traction Amplifier (TA) Traction Amplifier Removal Traction Amplifier Installation Programming the Traction Amplifier Motors, General Terminal Nuts Traction Motor Removal - Models 8HBW and 8HBE30/ Installation - Models 8HBW and 8HBE30/ Removal - Models 8HBC30/40 and 8TB Installation - Models 8HBC30/40 and 8TB Temperature Sensor Replacement Terminal Board Removal and Replacement Speed Sensor Replacement Motor Assembly Lift Motor General Data Lift Motor Removal Lift Motor Installation vi CL398-13, Issued: 6 May 2013
11 Toyota Pallet Truck Service Manual Table of Contents Hydraulic Components Hydraulic Components General Guidelines Hydraulic Fluid Checking Hydraulic Fluid Level Hydraulic Unit Hydraulic Unit Removal Hydraulic Unit Installation Hydraulic Reservoir Removal Installation Filter Screen and Suction Tube Removal Installation Hydraulic Pump Hydraulic Pump Removal Hydraulic Pump Installation Adjusting Hydraulic Pump Relief Valve Pressure Checking Relief Valve Setting Alternate Method Using Rated Load on Pallets Hydraulic Ram Inspection Hydraulic Ram Removal Hydraulic Ram Installation Hydraulic Cylinder Seals Cylinder Disassembly Cylinder Assembly Cast Hydraulic Cylinder Repair Disassembly Assembly Mast Top Linkage Subassembly Top Link Subassembly Removal Top Linkage Subassembly Installation Pull Rod Subassembly Removal Installation Load Wheels Tandem Load Wheels Models 8HBE and 8HBC Suspension Wheel Model 8TB Fork Height Adjustment Downstop Installation Downstop Adjustment Pallet Entry/Exit Enhancements CL398-13, Issued: 6 May 2013 vii
12 Table of Contents Toyota Pallet Truck Service Manual Options Cold Storage Conditioning Battery Spacer Kit Installation Part Selection Installation Battery Gate Interlock Sensors Battery Gate Interlock Sensor Replacement Battery Gate Interlock Sensor Adjustment Theory of Operation Definitions Acceleration Rate Brake Lever Potentiometer (VR1) (Models with Fixed Position Handle) 8-2 Brake (Deadman) Switch (Models 8HBW30, 8HBE30, or 8HBE40 with Spring-Loaded Handle) Continuity Controller Area Network (CAN) Current Limiting Emergency Reverse (Models 8HBW30 and 8HBE30 or 8HBE40) Fault Codes High Pedal Disable (HPD) Jog Speed Neutral Plugging Rate (Deceleration) Open Circuit Overvoltage Cutoff PIN-Key Code Pulse Width Modulation Ramp Shape Regenerative Braking Sequencing Delay Short Circuit or Short Speed Limiting Static Return To Off (SRO) Thermal Cutback (Traction Amplifier) Throttle Map Truck Off Delay (Keypad only) Undervoltage Cutoff VM (Vehicle Manager) Walking Speed Traction System Vehicle Manager (VM) Traction Amplifier (TA) Battery Plugged In Key Switch ON and M1 Energized Travel Request, Tractor-First Travel Request, Forks-First Strip Curtain Bypass (Model 8HBE30/40 only) Emergency Reverse (Model 8HBW30 and 8HBE30/40) Jog Mode Jog Pick Mode viii CL398-13, Issued: 6 May 2013
13 Toyota Pallet Truck Service Manual Table of Contents Lift/Lower System Lift Lower Theory of Operation - Electric Power Steering Power Steering Potentiometers Floor Mat Switch (SW25) - Model 8TB50 option Travel Speed Reduction PSU: Power Steering Unit Steering Pinout Matrix Appendix A-1 Lubrication Equivalency Chart A-2 Thread Adhesives, Sealants, and Lubricants A-3 Adhesives A-4 Component Specific Service/Torque Chart A-5 Torque Chart - Standard (Ferrous) A-8 Torque Chart - Standard (Brass) A-9 Torque Chart - Metric A-10 Torque Chart - Thread-Forming Screws A-11 Torque Chart - Hydraulic Fittings A-12 Torque Chart - Straight Thread Face Seal O-Rings A-13 Decimal Equivalent Chart A-14 Standard/Metric Conversions A-16 List of Electrical Symbols A-18 Schematics A-21 Electrical Schematics A-23 Power Distribution Diagram A-30 Hydraulic Schematic A-31 Index I CL398-13, Issued: 6 May 2013 ix
14 Table of Contents Toyota Pallet Truck Service Manual This page intentionally left blank. x CL398-13, Issued: 6 May 2013
Section 6. Messages and Codes
Toyota Pallet Truck Service Manual Section 6. Messages and Codes Section 6. Messages and Codes 00700-CL398-13, Issued: 6 May 2013 6-1 Service Manual Change History Description Page # Date Added Service
9 (229) 22 (559) or 24 (610) or 27 (686) 10 Lowered in (mm) 10 No Load %
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